Remote fluid supply for an engine

ABSTRACT

A system includes a first diesel engine operable to drive a first device, a first diesel exhaust fluid (“DEF”) tank associated with the first engine and operable to provide DEF to the first diesel engine during operation, a second diesel engine operable to drive a second device, a second DEF tank associated with the second engine and operable to provide DEF to the second diesel engine during operation, and an external DEF tank arranged to contain a quantity of DEF that is coupled to the first DEF tank and the second DEF tank and operable to selectively deliver DEF from the external DEF tank to each of the first DEF tank and the second DEF tank.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority as a continuation application of U.S.patent application Ser. No. 14/881,876, filed on Oct. 13, 2015 andentitled “Remote Fluid Supply for an Engine,” the contents of which ishereby incorporated by reference in its entirety.

BACKGROUND

Remote work sites regularly use engines and in particular diesel enginesto provide power to drive components such as generator systems. Thesesystems are often operated without supervision and without stop forextended periods of time. In operation, where a diesel engine is used, adiesel exhaust fluid (DEF) is often provided to treat the emissions ofthe engine.

SUMMARY

In one construction, the invention provides a system having a firstdiesel engine with a first local DEF tank, a second diesel engine with asecond local DEF tank, and an external DEF tank fluidly coupled to eachof the first and second local DEF tanks capable of selectivelydelivering DEF to the first and second local DEF tanks.

Another construction provides, a system that includes a first dieselengine operable to drive a first device, a first DEF tank associatedwith the first engine and operable to provide DEF to the first dieselengine during operation, a second diesel engine operable to drive asecond device, and a second DEF tank associated with the second engineand operable to provide DEF to the second diesel engine duringoperation. An external DEF tank is arranged to contain a quantity of DEFthat is coupled to the first DEF tank and the second DEF tank andoperable to selectively deliver DEF from the external DEF tank to eachof the first DEF tank and the second DEF tank.

Another construction provides, a system that includes a first dieselpowered generator positioned within a first housing, a first DEF tankpositioned within the first housing and operable to provide DEF to thefirst diesel powered generator during operation, and a first sensorcoupled to the first DEF tank and operable to detect a quantity of DEFwithin the first DEF tank. A second diesel powered generator ispositioned within a second housing, a second DEF tank is positionedwithin the second housing and is operable to provide DEF to the seconddiesel powered generator during operation, and a second sensor iscoupled to the second DEF tank and is operable to detect a quantity ofDEF within the second DEF tank. An external DEF tank is arranged tocontain a supply of DEF and a pump is associated with the external DEFtank and is operable in response to each of a detected first quantity ofDEF and a detected second quantity of DEF to selectively deliver DEFfrom the external DEF tank to each of the first DEF tank and the secondDEF tank.

Another construction provides a system that includes a first dieselpowered generator positioned within a first housing, a first DEF tankpositioned within the first housing and operable to provide DEF to thefirst diesel powered generator during operation, and a first sensorcoupled to the first DEF tank and operable to output a first signalindicative of a quantity of DEF within the first DEF tank. A seconddiesel powered generator is positioned within a second housing, a secondDEF tank is positioned within the second housing and is operable toprovide DEF to the second diesel powered generator during operation, anda second sensor is coupled to the second DEF tank and is operable tooutput a second signal indicative of a quantity of DEF within the secondDEF tank. An external DEF tank is arranged to contain a supply of DEFand a pump is associated with the external DEF tank and is operable topump fluid from the external DEF tank to each of the first DEF tank andthe second DEF tank. A controller is operable to receive the firstsignal and the second signal and operable to direct DEF from theexternal DEF tank to the first DEF tank in response to the first signalbeing indicative of a low level of DEF within the first DEF tank, andoperable to direct DEF from the external DEF tank to the second DEF tankin response to the second signal being indicative of a low level of DEFwithin the second DEF tank.

Other aspects of the invention will become apparent by consideration ofthe detailed description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of an external DEF tank coupled to a plurality ofgensets.

FIG. 1A is a detailed schematic of one genset of FIG. 1.

FIG. 2 is a schematic of a fluid coupling connecting the external DEFtank to one of the plurality gensets.

FIG. 3 is a schematic of an elevated external DEF tank coupled to aplurality of diesel engines.

FIG. 4 is a schematic of a plurality of auxiliary external DEF tankscoupled to a main external DEF tank that supplies at least one genset.

FIG. 5 is a schematic of a plurality of external DEF tanks fluidlycoupled to at least one genset.

Before any embodiments of the invention are explained in detail, it isto be understood that the invention is not limited in its application tothe details of construction and the arrangement of components set forthin the following description or illustrated in the following drawings.The invention is capable of other embodiments and of being practiced orof being carried out in various ways. Also, it is to be understood thatthe phraseology and terminology used herein is for the purpose ofdescription and should not be regarded as limiting. The use of“including,” “comprising,” or “having” and variations thereof herein ismeant to encompass the items listed thereafter and equivalents thereofas well as additional items. Unless specified or limited otherwise, theterms “mounted,” “connected,” “supported,” and “coupled” and variationsthereof are used broadly and encompass both direct and indirectmountings, connections, supports, and couplings. Further, “connected”and “coupled” are not restricted to physical or mechanical connectionsor couplings.

DETAILED DESCRIPTION

FIG. 1 illustrates a power generation system 1 that is operable toprovide electrical power in remote locations where electrical power maynot be readily available. The system 1 includes one or more gensets orpower generators 10 that each operate individually to produce electricalpower, an external diesel exhaust fluid (DEF) tank 100 fluidly coupledto each of the gensets 10, and a controller 200 to selectively deliverDEF to each genset 10. The system 1 operates to produce electrical powerin remote areas for extended periods of time without the need forregular user intervention.

With reference to FIG. 1A, each genset 10 includes an electricalgenerator 12, a prime mover 14 that operates to drive the electricalgenerator 12, and a fuel tank 16 supplying fuel to the prime mover 14.The generator 12 includes a single phase or multi-phase generator thatgenerates usable electrical power (DC or AC) at a desired voltage andfrequency in response to rotation produced by the prime mover 14.

In the illustrated construction, the prime mover 14 includes amulti-cylinder diesel engine 20 with other prime movers being possible(e.g., internal combustion engines, combustion turbines, etc.). In thisconstruction, the multi-cylinder diesel engine 20 includes an engineblock 22 having one or more cylinders or chambers 24, a piston 26disposed on the interior of each of the cylinders 24, and an outputshaft 28 coupled to the pistons 26. Each of the cylinders 24 has aninlet 30 including a fuel injector 32 supplying diesel fuel from thefuel tank 16, and an outlet 34 fluidly connected to an exhaust system40.

Each of the gensets 10 of FIGS. 1 and 1A further includes a local DEFtank 50 that is coupled to the exhaust system 40. The local DEF tanks 50include an outer wall 52 defining a first volume 54, an inlet 56, anoutlet 58 coupled to one or more DEF injectors 60 of the exhaust system40, and a sensor 70 that measures an amount of DEF held in the local DEFtank 50 (e.g., liquid level sensor, load sensor, etc.) to generate acorresponding first signal 72 (FIG. 2). The exhaust system 40 of thegenset 10 allows combustion products (e.g., CO₂, H₂O, NO_(R), etc.)created in the diesel engine 20 when diesel fuel is burned to betransported from the cylinders 24 to the surrounding atmosphere throughone or more exhaust pipes 42. The exhaust system 40 and the local DEFtank 50 are fluidly connected, with the DEF injectors 60 supplying theDEF stored in the local DEF tank 50 to the each of the exhaust pipes 42.The DEF is used to treat the combustion products, which contain a groupof compounds collectively referred to as NO_(R), in order to reduceNO_(x) concentration in the combustion products via a selectivecatalytic reduction reaction as the combustion products move through theexhaust pipes 42.

FIG. 1 also illustrates the external DEF tank 100 fluidly coupled toeach of the local DEF tanks 50 of each genset 10. The external DEF tank100 includes an outer wall 102 defining a second volume 104, a refillingaperture 106, and an outlet 108 fluidly connected to an inlet 122 of afluid coupling member or manifold 120. The external DEF tank 100 holdsthe second volume 104 of DEF that is substantially greater than thefirst volume 54 held in each of the local DEF tanks 50. DEF may beintroduced through the refilling aperture 106, which has a removable cap112 having an open and closed configuration. DEF can be added to theexternal DEF tank 100 when the cap 112 is in an open configuration, butthe external DEF tank 100 is sealed from spillage of DEF and outsidecontaminants when the cap 112 is in a closed configuration. In theillustrated construction, the outlet 108 of the tank provides a fluidpathway connecting the external DEF tank 100 to the manifold 120, andthus forms a first portion of a connection between the external DEF tank100 and the local DEF tanks 50 of the gensets 10. However, in otherembodiments of the invention (not shown), the external DEF tank 100 mayhave a plurality of outlets, where each outlet defines a portion of oneof multiple discrete fluid pathways connecting the external DEF tank 100and each of the local DEF tanks 50 of each of the gensets 10.

FIG. 2 shows an enlarged view of the fluid coupling or manifold 120 ofFIG. 1. The manifold 120 includes the inlet 122 and a plurality ofoutlets 124 each corresponding to one of the local DEF tanks 50 of eachgenset 10. Each of the plurality of outlets 124 includes a solenoidoperated valve 130 that is operated by a switch 132 to be selectivelymoveable between an open configuration 140 and a closed configuration150. In the open configuration 140, DEF is allowed to flow from theexternal DEF tank 100 to the local DEF tank 50 corresponding to theoutlet 124. In the closed configuration 150, DEF flow is stopped at thevalve 130. In this construction, a pump 160 (FIG. 1) is provided tocreate a driving pressure 170 in order to move DEF from the externaltank 100, through the manifold 120, and to the local DEF tanks 50. Thepump 160 shown is a fluid pump actively pressurizing fluid and drivingflow. However, any other suitable configurations in which a pumpgenerates a driving pressure, such as a pump disposed on the externalDEF tank 100 functioning to pressurize the tank, may be used.

The controller 200 is operatively connected to each sensor 70 of eachlocal DEF tank 50 and the switch 132 that is operatively connected toeach solenoid operated valve 130. The controller 200 is configured toreceive the first signal 72 from the sensor 70 of each local DEF tank50, and determine if that signal 72 corresponds to a low fluid level(e.g., a fluid level below a predetermined value) or a high fluid level.The controller 200 is further capable of controlling the switch 132 inorder to energize or de-energize the solenoid operated valve 130 andmove it to the open 140 or the closed configuration 150. In preferredconstructions, the controller includes a microprocessor basedcontroller. However, other controllers may include PLCs or even simpleanalog controllers.

In another construction, multiple controllers 200 may be connected toone or more sensors 70 of each local DEF tank 50 and to one or moreswitches 132 operatively connected to each solenoid valve 130. In otherwords, each controller 200 may operate multiple solenoid operated valves130. In a preferred construction, each sensor 70 and solenoid operatedvalve 130 associated with each local DEF tank 50 is operated by anindividual controller 200.

In another construction, the sensor 70 includes a liquid level switchthat directly opens and closes a circuit to the solenoid valve 130. Inthis arrangement, the controller 200 is distributed between the varioussensor switches 132. In this construction, when the liquid level dropsbelow a certain value, the switch is closed and the solenoid valve 130is actuated to allow flow to the local DEF tank 50. As the fluid levelrises, it eventually reaches a high level and the switch 132 moves to anopen position which opens the circuit and de-energizes the solenoidvalve 130 to stop the flow of DEF to the local DEF tank 50.

In yet another construction, a simple mechanical controller is employed.The mechanical controller includes a float valve that opens and closes aflow path to control the flow of fluid from the external DEF tank 100 tothe local DEF tank 50.

In operation of the construction of FIGS. 1 and 2, diesel fuel isprovided to each genset's 10 diesel engine 20 and combusted to produceshaft power and a flow of exhaust gases. The shaft power directly orindirectly drives the generator 12 to provide the desired electricalpower. The exhaust gases flow through the engine exhaust system 40 wherevarious cleaning and treating processes may occur before discharging theexhaust gas into the atmosphere. DEF is drawn from the local DEF tank 50of each genset 10 and injected into the exhaust stream. The DEF reactswith the exhaust gas to break down the undesirable NOx emissions toprovide a more desirable exhaust gas make-up. As DEF is drawn from thelocal DEF tank 50, the level of DEF will drop. Eventually, thecontroller 200 receives the signal 72, determines it is indicative of alow DEF level, and actuates the switch 132 of the solenoid operatedvalve 130 that leads to the particular local DEF tank 50 that isexperiencing the low level. The solenoid operated valve 130 is energizedand moved to the open configuration 140, and DEF is now free to flowfrom the external DEF tank 100 to the local DEF tank 50. The controller200 eventually determines the signal 72 is indicative of a high levelwithin the local DEF tank 50 and the controller 200 actuates the switch132 of the solenoid operated valve 130, causing the solenoid operatedvalve 130 to be de-energized thereby moving the valve to the closedconfiguration 150. In other constructions, the controller 200 mayoperate to allow the valve to stay open a predetermined amount of timeor any other acceptable operation for selectively operating the valve130 to allow fluid flow to fill the local DEF tanks 50.

An alternate embodiment of a power generation system, similar to the oneshown in FIG. 1, is illustrated in FIG. 3. In this construction, thepump 160 and controller 200 are omitted. This description will focus onthe aspects of the embodiment shown that are different from theembodiment shown in FIG. 1. It should be noted, however, that anyfeatures and alternatives presented in this embodiment may beincorporated or substituted into the embodiment of FIG. 1 or vice versa.

With reference to FIG. 3, an external DEF tank 500 of this embodiment iselevated by a height H. The height H is substantially greater than aheight of each of the local DEF tanks 50 disposed in the gensets 10. Theexternal DEF tank 500 of FIG. 3 includes an outlet 508 disposed near thebottom of an outer wall. However, it should be noted that the outlet maybe located in any position (e.g., on the lower surface of the tank)where the DEF in the tank uses the hydrostatic force produced byelevation (e.g., height H) of the fluid in the tank to provide drivingpressure 170 that moves the DEF through the outlet 508 and to theplurality of local DEF tanks 50.

With continued reference to FIG. 3, the fluid leaves the outlet 508 ofthe external DEF tank 500 and enters an inlet 302 of a manifold 300. Themanifold 300 has a plurality of outlets 304 that lead along a pluralityof flow paths 306 to each of the local DEF tanks 50, where they entereach local DEF tank 50 through an inlet 52. Each flow path 306 may beequipped with a flow restriction device 310 that controls the pressuredrop through the flow path 306 and therefore the amount of fluid passedto each local DEF tank 50. The inlet 352 of each local DEF tank 50 isbelow a fluid level line 320 defined by the level of fluid on theinterior of each local DEF tank 50, which also defines an inletresistance. The driving pressure 170 is determined based on thedifference in the level of fluid 520 within the local DEF tanks 50 andthe level of the fluid within the external DEF tank 500. The differencein the liquid levels defines a pressure gradient that can produce anatural flow from the external DEF tank 500 to the local DEF tank 50 solong as a flow resistance (e.g., inlet resistance, friction, length ofpipe, flow obstructions, etc.) is not greater than the pressuregradient. Since the driving pressure 170 is governed by the force ofgravity on the DEF in the external DEF tank 500, the flow restrictiondevices 310 may operate to restrict or permit flow based on changingpressures as the external DEF tank 500 empties (thus altering thedriving pressure 170) to maintain a substantially constant amount of DEFin the local DEF tanks 50.

The flow restriction devices 310 may include an electronically actuatedsolenoid valve, a float valve, or a butterfly valve operated by apressure switch, a passive flow limiter, or any other device suitablefor governing fluid flow based on predetermined parameters. In otherconstructions, the flow restriction device 310 may be disposed on theindividual local DEF tanks 50 to selectively operate DEF flow at theinlet 352 of the local DEF tank 50, or a single flow restriction device310 may be placed on the outlet 508 of the external DEF tank 500 togovern flow and maintain the same level of DEF in each local DEF tank50.

FIG. 4 illustrates yet another embodiment of the power generationsystem, which is similar to the embodiments shown in FIGS. 1 and 3. Thisdescription will focus on the aspects of the embodiment shown that aredifferent from the embodiments shown in FIGS. 1 and 3. It should benoted, however, that any features and alternatives presented in thisembodiment may be incorporated or substituted into the embodiment ofFIGS. 1 and 3, or vice versa.

With reference to FIG. 4, one or more auxiliary external DEF tanks 650are fluidly coupled to a main external DEF tank 600 in order to supplythe main external DEF tank 600 with reserve DEF. In the illustratedconstruction, each auxiliary external DEF tank 650 includes a pump 660to selectively deliver DEF from the auxiliary external DEF tank 650 tothe main external DEF tank 600. In an alternate construction, the DEFfrom the auxiliary external DEF tanks 650 may be fed into the mainexternal DEF tank 600 via a gravity feed system similar to the mechanismfor delivery of DEF from the external DEF tank 500 to gensets 10illustrated in FIG. 3. Furthermore, each auxiliary external DEF tank 650may optionally be fluidly coupled to a manifold (not shown) that iscoupled to the main external DEF tank 600 via a single, regulated flowpath to maintain DEF levels within the main external DEF tank 600.

FIG. 5 illustrates another embodiment of the power generation system,which is similar to the embodiments shown in FIGS. 1, 3 and 4. Thisdescription will focus on the aspects of the embodiment shown that aredifferent from the embodiments shown in FIGS. 1, 3 and 4. It should benoted, however, that any features and alternatives presented in thisembodiment may be incorporated or substituted into the embodiment ofFIGS. 1, 3 and 4, or vice versa.

With reference to FIG. 5, two or more external DEF tanks 700 are eachconnected to a first manifold 710, which may be similar to manifolds 120or 300 illustrated in FIGS. 1 and 3, respectively, in all aspects exceptDEF flows in an opposite direction thereby converging to a main DEF line730. A second manifold 720, similar to the manifolds 120 or 300 in FIGS.1 and 3, respectively, is coupled to the main DEF line 730 downstream ofthe first manifold 710 in order to selectively direct DEF to each genset10. In this system, DEF may be delivered from the external tanks to thegensets 10 via the mechanisms described with reference to FIGS. 1 and 3(i.e., utilizing pumps or a gravity feed), or any other suitablemechanism.

In the constructions set forth above, local DEF tanks maintain anoperational amount of DEF as supplied by the external DEF tanks forextended periods of time. This allows for unmanned function (e.g.,removing the need for multiple local DEF tank refueling accomplishedmanually by a user) over longer periods of time than traditionalunmanned gensets. For remote locations where user intervention isdifficult or unavailable, as well as for decreasing the need forintervention in any environment, this power generation system representsa significant advantage.

Various features and advantages of the invention are set forth in thefollowing claims.

What is claimed is:
 1. A system comprising: a first diesel engineoperable to drive a first device; a first diesel exhaust fluid (“DEF”)tank associated with the first engine and operable to provide DEF to thefirst diesel engine during operation; a second diesel engine operable todrive a second device; a second DEF tank associated with the secondengine and operable to provide DEF to the second diesel engine duringoperation; and an external DEF tank arranged to contain a quantity ofDEF that is coupled to the first DEF tank and the second DEF tank andoperable to selectively deliver DEF from the external DEF tank to eachof the first DEF tank and the second DEF tank.
 2. The system of claim 1,further comprising a pump operable to deliver DEF from the external DEFtank to each of the first DEF tank and the second DEF tank.
 3. Thesystem of claim 1, wherein the first device is a generator and thesecond device is a generator.
 4. The system of claim 2, furthercomprising a first sensor coupled to the first DEF tank and operable tooutput a first signal indicative of a quantity of DEF within the firstDEF tank, and a second sensor coupled to the second DEF tank andoperable to output a second signal indicative of a quantity of DEFwithin the second DEF tank.
 5. The system of claim 4, wherein the firstsensor is a liquid level sensor and the second sensor is a liquid levelsensor.
 6. The system of claim 4, further comprising a controlleroperable to receive the first signal and the second signal and operableto activate the pump to direct DEF from the external DEF tank to thefirst DEF tank in response to the first signal being indicative of a lowlevel of DEF within the first DEF tank, and operable to activate thepump to direct DEF from the external DEF tank to the second DEF tank inresponse to the second signal being indicative of a low level of DEFwithin the second DEF tank.
 7. The system of claim 2, further comprisinga manifold including an inlet and a plurality of outlets, wherein thepump delivers DEF to the inlet and wherein a first of the plurality ofoutlets is fluidly coupled to the first DEF tank and a second of theplurality of outlets is fluidly coupled to the second DEF tank.
 8. Thesystem of claim 7, further comprising a plurality of valves, each valveassociated with one of the plurality of outlets, wherein each valve ismovable between a closed position in which no DEF flows through theoutlet and an open position in which DEF flows through the outlet. 9.The system of claim 8, wherein the valves are solenoid operated valves,and wherein a controller selectively actuates the solenoids to move thevalves between the open position and the closed position.